Apparatus and Method for Making Inflated Articles

ABSTRACT

A sealing device generally includes a rotatable support cylinder having an outer, circumferential surface and a heating element disposed about such surface and secured thereto such that the heating element rotates therewith. The heating element is coiled about the outer surface of the cylinder in the form of an overlapping helical pattern. Juxtaposed film plies may be sealed together by bringing the sealing device into rotational contact with the juxtaposed film plies and heating the heating element to a temperature sufficient to cause the film plies to seal together.

This application is a continuation of U.S. patent application Ser. No.16/011,999, filed Jun. 19, 2018, which is a continuation of U.S. patentapplication Ser. No. 14/033,704, filed Sep. 23, 2013, which is adivisional of U.S. patent application Ser. No. 11/786,631, filed Apr.12, 2007, the disclosures of which are hereby incorporated by referencein their entirety.

BACKGROUND

The present invention relates to inflated containers and, moreparticularly, to an improved apparatus and process for producinggas-inflated containers having one or more compartments that fluidlycommunicate with one another.

Various apparatus and methods for forming inflated cushions, pillows, orother inflated containers are known. Inflated cushions are used topackage items, by wrapping the items in the cushions and placing thewrapped items in a shipping carton, or simply placing one or moreinflated cushions inside of a shipping carton along with an item to beshipped. The cushions protect the packaged item by absorbing impactsthat may otherwise be fully transmitted to the packaged item duringtransit, and also restrict movement of the packaged item within thecarton to further reduce the likelihood of damage to the item.

Many conventional inflatable cushions have the form of an inflated bag.While very useful in many packaging applications, such bag-type cushionscannot be wrapped around an object to be packaged.

Some inflatable cushions include a plurality of inflatable chambers,with partitions separating the individual chambers. The partitions allowthe cushion to be wrapped about an object. However, such cushioning isgenerally of the pre-formed type, i.e., wherein the individual chambersare pre-fabricated at a factory or other non-packaging location. Thisincreases the material cost to the packager, and often requires thatseveral different types, e.g., sizes, styles, shapes, etc., ofinflatable cushioning be kept by the packager in order to be able toadequately package objects having different sizes, shapes, etc. Not onlydoes this further increase the material cost to the packager, but thenecessity of changing cushioning types is cumbersome and requires a slowdown in the rate at which objects can be packaged. Moreover, variationsin the process of making pre-formed cushions can cause alignment andtracking problems in the inflation/sealing machines, resulting inpoorly-inflated and/or poorly-sealed cushions, which may deflateprematurely or otherwise fail to protect the packaged product.

Accordingly, there is a need in the art for an apparatus and process formaking, inflating, and sealing inflated containers that have one or morecompartments in fluid communication with one another. This would allowsuch cushions to be formed at a packaging site and then wrapped aboutobjects to be packaged.

SUMMARY

That need is met by the present invention, which, in one aspect,provides a sealing device, comprising: a. a rotatable support cylinderhaving an outer, circumferential surface; and b. a heating elementdisposed about at least a portion of the outer surface and securedthereto such that the heating element rotates therewith, the heatingelement being coiled about the outer surface in the form of anoverlapping helical pattern, whereby, juxtaposed film plies may besealed together by bringing the device into rotational contact with thejuxtaposed film plies and heating the heating element to a temperaturesufficient to cause the film plies to seal together.

The heating element may be coiled at least twice about the outer surfaceof the cylinder to form at least a double helical pattern.

The sealing device may further include a backing roller, wherein therotatable support cylinder and the backing roller are structured andarranged to rotate against one another to create an area of tangentialcontact therebetween, which exerts a rotational compressive force on thefilm plies.

The sealing device may further include a drive mechanism to power therotation of at least one of the support cylinder and the backing roller.

The film plies may be bonded together with a series of transverse seals,and the sealing device may produce a discontinuous series oflongitudinal seals that intersect the transverse seals.

Another aspect of the invention is directed towards an apparatus formaking inflated containers from a film web having two juxtaposed filmplies, comprising: a. a first sealing device for producing a series oftransverse seals that bond the film plies together; b. an inflationassembly for directing gas between the film plies; and c. a secondsealing device for producing a discontinuous series of longitudinalseals that bond the film plies together and intersect the transverseseals to enclose the gas between the film plies to thereby form inflatedcontainers, the second sealing device comprising: 1) a rotatable supportcylinder having an outer, circumferential surface, and 2) a heatingelement disposed about at least a portion of the outer surface andsecured thereto such that the heating element rotates therewith, theheating element being coiled about the outer surface in the form of anoverlapping helical pattern, whereby, the longitudinal seals are formedby bringing the second sealing device into rotational contact with thejuxtaposed film plies and heating the heating element to a temperaturesufficient to cause the film plies to seal together.

A further aspect of the invention pertains to a method for makinginflated containers from a film web having two juxtaposed film plies,comprising: a. producing a series of transverse seals that bond the filmplies together; b. directing gas between the film plies; and c.producing a discontinuous series of longitudinal seals that bond thefilm plies together and intersect the transverse seals to enclose thegas between the film plies to thereby form inflated containers, whereinthe longitudinal seals are formed by 1) bringing a sealing device intorotational contact with the juxtaposed film plies, the sealing devicecomprising a heating element coiled about at least a portion of an outersurface of a rotatable support cylinder in an overlapping helicalpattern and secured thereto such that the heating element rotatestherewith, and 2) heating the heating element to a temperaturesufficient to cause the film plies to seal together.

These and other aspects and features of the invention may be betterunderstood with reference to the following description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a schematic elevational view of an apparatus for forminginflated containers in accordance with the present invention;

FIG. 2 is a perspective view of the apparatus shown in FIG. 1;

FIG. 3 is an enlarged, perspective view of the sealing roller 48 asshown in FIG. 2;

FIG. 4 is a plan view of inflated containers made from a modifiedversion of the apparatus shown in FIG. 1, wherein a longitudinal sealingroller 80 as shown in FIG. 5 is used in place of the sealing roller 70as shown in FIGS. 1-2;

FIG. 5 is an elevational view of a longitudinal sealing roller, whichmay be used in place of the sealing roller 70 as shown in FIGS. 1-2;

FIG. 6 is a more detailed view of the sealing roller 48 as shown in FIG.3;

FIG. 7 is a schematic elevational view of an alternative apparatus forforming inflated containers in accordance with the present invention;

FIG. 8 is a perspective view of the apparatus shown in FIG. 7;

FIG. 9 is a plan view of intermediate sealing element 210 as shown inFIG. 8;

FIG. 10 is a schematic elevational view of another alternative apparatusfor forming inflated containers in accordance with the presentinvention;

FIG. 11 is a perspective view of the apparatus shown in FIG. 10;

FIG. 12 is a schematic elevational view of a further alternativeapparatus for forming inflated containers in accordance with the presentinvention;

FIG. 13 is a perspective view of the apparatus shown in FIG. 12;

FIG. 14A is an enlarged, elevational view of component 416 a of firstsealing device 406 as shown in FIGS. 12-13;

FIG. 14B is similar to FIG. 14A, but illustrates an alternativearrangement of the sealing elements on component 416 a;

FIG. 15 is a detailed perspective view of the movable components 416 a,b of first sealing device 406 as shown in FIGS. 12-13;

FIG. 16 is a schematic elevational view of another alternative apparatusfor forming inflated containers in accordance with the presentinvention;

FIG. 17 is a perspective view of the apparatus shown in FIG. 16;

FIG. 18 is a perspective view of an alternative longitudinal sealingroller, which includes a sealing element having a double helicalpattern;

FIG. 19 is a plan view of inflated containers having a longitudinal sealformed by the sealing roller shown in FIG. 18; and

FIG. 20 is a plan view of inflated containers having a longitudinal sealformed by an alternative synchronization of the sealing roller shown inFIG. 18.

DETAILED DESCRIPTION

Referring to FIGS. 1-2, there is shown an apparatus 10 in accordancewith the present invention for making inflated containers 12 from a filmweb 14 having two juxtaposed film plies 16 and 18. Inflated containers12 may be used as cushions, e.g., for packaging and protecting itemsduring shipment and storage. Other uses for the inflated containers arealso envisioned, e.g., as floatation devices or decorative objects.

As shown, apparatus 10 includes a first sealing device 20, an inflationassembly 22, a second sealing device 24, and at least one intermediatesealing element 26.

First sealing device 20 produces a series of transverse seals 28 thatbond the juxtaposed film plies 16, 18 together. Such seals are generallyoriented in a direction that is substantially transverse, i.e., at anangle, to the direction of movement of film web 14 along its travel paththrough apparatus 10. Pre-inflated containers 30 may thus be formedbetween pairs of the transverse seals 28. Such transverse seals 28 willalso be components of the completed, inflated containers 12. For ease ofreference, the ‘upstream’ transverse seal of each container 12, 30 isdesignated 28 a while the ‘downstream’ seal is designated 28 b.

Inflation assembly 22 directs gas, indicated by arrow 32, between filmplies 16, 18 and into the pre-inflated containers 30 as shown.

Second sealing device 24 produces one or more longitudinal seals thatbond the film plies 16, 18 together. In the presently-illustratedembodiment, second sealing device 24 produces a single, continuouslongitudinal seal 34. In other embodiments, the second sealing devicemay produce a discontinuous series of longitudinal seals as disclosed,e.g., in U.S. Ser. No. 11/099,289, published under Publication NumberUS-2006-0218880-A1, the disclosure of which is hereby incorporated byreference herein.

In order to form inflated containers 12, apparatus 10 forms transverseseals 28 and longitudinal seal(s) 34 in such a manner that the seals 28,34 intersect, thereby enclosing gas 32 between film plies 16, 18.

In the illustrated embodiment, film web 14 is a ‘center-folded’ webhaving a closed longitudinal edge 36 and an opposing open longitudinaledge 38. Open longitudinal edge 38 allows gas 32 to be directed betweenfilm plies 16, 18 and into the pre-inflated containers 30. Closedlongitudinal edge 36 may be formed by folding film web 14 at or near itslongitudinal center, i.e., center-folding the web, such that each of thefilm plies 16, 18 have substantially the same dimension. Suitablecenter-folding devices and methods are well-known in the art.Center-folding may be performed at any desired time, e.g., shortly afterthe film is produced and/or just before being wound onto a supply roll(not shown) for later use with apparatus 10. Alternatively, acenter-folding device may be added to or used with apparatus 10 at alocation upstream of the apparatus.

As a further alternative, separate film plies 16, 18 may be juxtaposedand sealed together along adjacent longitudinal side edges, e.g., viaheat-sealing, to form closed longitudinal edge 36.

As another alternative, film web 14 may be a flattened tube, i.e., withtwo opposing folded/closed longitudinal edges joining the juxtaposedfilm plies 16, 18. In other words, when film web is a tube, both oflongitudinal edges 36, 38 are closed, e.g., folded or sealed. In oneembodiment, one of the longitudinal edges may be slit at some point‘upstream’ of inflation assembly 22 to form open edge 38. In anotherembodiment, inflation may be effected by inserting one or more needlesinto the tube, injecting air through the needles, then sealing theresultant needle holes to enclose gas within the tube. Sealing of theneedle holes may be accomplished by forming a pair of transverse seals,with one transverse seal formed upstream of the needles holes and thesecond transverse seal formed downstream of the needle holes, therebyisolating the needle holes between the pair of transverse seals. In thisembodiment, second sealing device 24 would not be needed and could beomitted from the apparatus. Further details regarding this means forforming inflated containers from a tube are set forth in U.S. Pat. No.5,942,076, the disclosure of which is hereby incorporated by referenceherein.

Because apparatus 10 inflates the film web 14 from one edge thereof, avariety of web widths may be accommodated by the apparatus, therebymaking inflated containers having a variety of widths ranging, e.g.,from 4 inches to 20 inches.

Accordingly, when second sealing device 24 makes longitudinal seal 34,gas 32 is enclosed between: film plies 16, 18; a pair 28 a, b oftransverse seals; closed longitudinal edge 36; and longitudinal seal 34.In this manner, each pre-inflated container 30 is converted into aninflated container 12.

In accordance with the present invention, apparatus 10 further includesat least one intermediate sealing element 26 for producing one or moreintermediate seals 40 within each inflated container 12. In thepresently-illustrated embodiment, apparatus 10 includes threeintermediate sealing elements 26, 26 a, and 26 b, which form threeintermediate seals 40, 40 a, and 40 b in each inflated container 12. Asshown, the intermediate seals 40-40 b partition the inflated containers12 into two or more compartments 42 a-42 d, and provide at least oneflow passageway 44 between at least two of the compartments to allowsuch compartments to fluidly communicate with one another (see also FIG.4).

Accordingly, unlike longitudinal seal 34, which intersects thetransverse seals 28 a, b for each container to enclose gas 32 therein,the intermediate seals 40-40 b preferably do not intersect bothtransverse seals. In this manner, at least one gap or space existsbetween the intermediate seals and a transverse seal, which provides theflow passageways 44 between each of the compartments 42 a-42 d. In theillustrated embodiment, the intermediate seals 40 intersect neithertransverse seal 28 a nor 28 b so that two flow passageways 44 areassociated with each intermediate seal 40-40 b: one flow passageway 44is positioned between each intermediate seal and each upstreamtransverse seal 28 a and another flow passageway is located between eachintermediate seal and each downstream transverse seal 28 b.

Each of intermediate sealing elements 26-26 b may provide suchintermediate seals 40-40 b by forming a series of longitudinally arrayed‘skip seals,’ which are longitudinally discontinuous, i.e., spaced fromone another in the longitudinal direction, and positioned between eachof the transverse seals 28 a, b, such that each skip seal becomes anintermediate seal. This may be accomplished, as illustrated, byfashioning first sealing device 20 such that it comprises both atransverse sealing element 46 and intermediate sealing elements 26-26 b.Further, first sealing device 20 may comprise at least one rotarycomponent, such as sealing roller 48, on the surface of which thetransverse and intermediate sealing elements may be mounted as shown.

In the presently described embodiment, first sealing device 20 mayinclude a plurality of transverse sealing elements, including transversesealing elements 46, 46 a, 46 b, and 46 c. As shown, the transversesealing elements may be paired, e.g., with elements 46, 46 a pairedtogether and elements 46 b, 46 c paired together. Further, each pair maybe positioned on the sealing roller 48 with any desired degree ofangular spacing between each pair, e.g., with 180° spacing as shown.Similarly, each of intermediate sealing elements 26, 26 a, and 26 b mayhave an opposing counterpart sealing element 26 c, 26 d, and 26 e,respectively (only element 26 e shown), on sealing roller 48, e.g., atan angular spacing of 180° as illustrated. In this manner, when rotarycomponent 48 rotates, the transverse sealing elements and intermediatesealing elements intermittently contact web film 14 to alternatinglyform transverse seals 28 and intermediate seals 40 as shown.

Apparatus 10 may further include a mechanism that conveys the film web14 along a path of travel through the apparatus as shown. Suchconveyance mechanism may be provided by including in first sealingdevice 20 a further rotary component, e.g., backing roller 50. Thesealing and backing rollers 48, 50 may be relatively positioned suchthat they rotate against one another to create a ‘nip,’ or area oftangential contact, therebetween, which exerts a rotational compressiveforce on film web 14. As such, sealing and backing rollers 48, 50 may beused to convey the film web through apparatus 10 when the rollers rotatein the direction indicated by the rotational arrows in FIG. 1, whichthereby drives the film web in a forward direction as indicated by thelinear arrow in FIG. 2. Thus, as a further component of the conveyancemechanism, the rotation of one or both rollers 48, 50 may be powered bya suitable drive mechanism.

For example, a motor 52 may be included, which is mechanically linked tosealing roller 48 as shown schematically in FIG. 2. In suchconfiguration, sealing roller 48 serves as a ‘drive roller’ whilebacking roller 50 is a ‘driven roller,’ i.e., passively driven bydrive/sealing roller 48. Alternatively or in addition, a motor maysimilarly be linked to backing roller 50 to directly drive the rotationthereof.

The ‘path of travel’ (or ‘travel path’) is simply the route that filmweb 14 follows as it is conveyed through apparatus 10. Thus, in thepresently illustrated embodiment, film web 14 is conveyed throughapparatus 10 along a travel path that encounters the followingcomponents, in the following order: first sealing device 20, guideroller 54, inflation assembly 22, and second sealing device 24. Theforegoing order is in no way intended to be limiting, and is merely setforth for illustration. Numerous other configurations are possible, someof which are described below. Guide roller 54 may be included asnecessary, e.g., to place film web 14 in alignment with inflationassembly 22. Various additional conventional film-guide and film-drivedevices may be included as desired.

Film web 14 may be supplied, e.g., from a supply roll (not shown) thatis positioned, e.g., above or beneath the components depicted in FIGS.1-2 and mounted, e.g., to the same frame or housing to which the othercomponents of apparatus 10 are mounted. Alternatively, the film web maybe supplied from a separate film-supply mechanism, such as acart-mounted roll or a folded stack housed in a box.

Accordingly, it may be appreciated that the rotary component, i.e.,sealing roller, 48 of first sealing device 20 is adapted to bring thetransverse and intermediate sealing elements 46, 26 into rotationalcontact with film web 14 as the web is conveyed along its travel paththrough apparatus 10. In this manner, first sealing device 20 forms thetransverse seals 28 and intermediate seals 40 as the film web isconveyed along such travel path.

Specifically, it may be seen in FIGS. 1-2 that as sealing roller 48continues to rotate in the direction shown, transverse sealing element46 a will next be brought into contact with film web 14, followed bytransverse sealing element 46, to produce respective transverse seals 28a and 28 b in the relatively closely-spaced, paired relationshipsillustrated in FIG. 2. As the roller 48 continues its rotation,intermediate sealing elements 26, 26 a, and 26 b will contact the filmweb, thereby producing respective intermediate seals 40, 40 a, and 40 b,which are spaced and positioned just ‘upstream’ from the just-formedtransverse seal 28 b. Upon further rotation of roller 48, transversesealing elements 46 c and 46 b will make another pair of respectivetransverse seals 28 a and 28 b. The resultant transverse seal 28 a madeby transverse sealing element 46 c thus completes the pre-inflatedcontainer 30 begun by the formation of transverse seal 28 b bytransverse sealing element 46 on the previous half rotation of sealingroller 48. Similarly, the transverse seal 28 b made by transversesealing element 46 b will begin the formation a new pre-inflatedcontainer 30, to which a set of intermediate seals 40, 40 a, and 40 bare added by intermediate sealing elements 26 c-26 e (only element 26 eshown) upon further rotation of sealing roller 48.

Accordingly, although apparatus 10 produces the transverse andintermediate seals on an intermittent and alternating basis, therotation of the sealing and backing rollers 48, 50 may be continuoussuch that the film web may move continuously, i.e., without stoppage orinterruption, through apparatus 10.

The transverse, intermediate, and longitudinal seals 28, 34, and 40,respectively, may be any type of seal that bonds two film pliestogether, such as a heat seal, adhesive seal, cohesive seal, etc., withheat seals being preferred. A heat seal, or heat weld, may be formedwhen the film plies 16, 18 are brought into contact with one another andsufficient heat is applied to one or both films in one or morepredetermined regions such that at least a portion of each heated filmregion becomes molten and intermixes with the other heated region. Uponcooling, the heated regions of the two film plies become bound together.The heated regions are thereby transformed into heat seals, which mayserve as seals 28, 34, and 40 as shown in FIG. 2.

Referring now to FIG. 3, a suitable embodiment for first sealing device20 will be described in further detail. The rotary ‘sealing roller’component 48 of device 20 may comprise a rotatable support cylinderhaving an outer, circumferential surface 56 and an axis 58 about whichthe cylinder rotates. Transverse sealing elements 46 and 46 a may beaffixed to the outer surface 56 in substantial alignment with axis 58. Asecond pair of transverse sealing elements, e.g., 46 b and 46 c, or evena third or fourth pair may similarly be affixed to the outer surface 56,at any desired degree of spacing from elements 46 and 46 a. For clarity,only transverse sealing elements 46 and 46 a are shown in FIG. 3; theintermediate sealing elements 26 and other transverse sealing elementshave been omitted from this view.

Transverse sealing elements 46 and 46 a may be resistive elements, whichproduce heat when electricity is supplied thereto (source not shown),and can have any desired shape or configuration. As shown, elements 46and 46 a are in the form of linear, substantially parallel wires, whichproduce a pair of substantially parallel transverse heat seals 28 a, bin film web 14 when elements 46/46 a are brought into contact therewith,e.g., as illustrated in FIGS. 1-2. In this manner, first sealing device20 forms transverse seals 28 a, b when sealing roller 48 is brought intorotational contact with one of film plies 16 or 18, and the sealingelements 46/46 a are heated to a sealing temperature sufficient to causethe film plies to seal together. When sealing roller 48 is configured asshown in FIGS. 1-2, i.e., with two pairs of sealing elements 46/46 a and46 b/46 c arrayed on the surface 56 of roller 48, then two pairs 28 a, bof transverse seals 28 are created with each rotation of roller 48.Similarly, three pairs of sealing elements on roller 48 would producethree pairs 28 a, b of transverse seals with each rotation, etc.

As an alternative or in addition to the substantially linear seals 28that are depicted in FIG. 2, other shapes and patterns may also beformed, such as substantially non-linear seals, e.g., undulating sealsthat produce a pattern of interconnected bubbles, seals with acombination of linear and non-linear segments (described below),‘zig-zag’ seal patterns, etc.

If necessary or desired, a heat transfer medium may be placed betweenthe transverse sealing elements 46/46 a and the film web 14, such as acoating of PTFE, e.g., TEFLON tape, polyester, or other material capableof withstanding the heat from the sealing members and transferring thesame to the film web in an amount sufficient to create seals 28.

Upon completion of the individual inflated containers 12, theirseparation from one another and/or from film web 14 may be facilitatedby including one or more lines of weakness 60 between adjacent articles(see FIGS. 2 and 4; only one line of weakness 60 shown). Accordingly,apparatus 10 may advantageously include means for producing such linesof weakness. This may be accomplished by adapting first rotary sealingdevice 20 to produce lines of weakness 60 between pre-inflatedcontainers 30, e.g., either between each container or between groups oftwo or more containers as desired. For example, a device for creatinglines of weakness 60 may be incorporated into or onto, e.g., affixed to,sealing roller 48 at outer surface 56 thereof.

A suitable device for creating lines of weakness 60 is a perforationblade 62, which produces a perforation-type line of weakness. As shownin FIG. 3, perforation blade 62 may be incorporated as a component ofsealing roller 48. Blade 62 may be serrated as shown to produce a row ofperforations in film web 14, which form lines of weakness 60 in film web14 to allow easy tearing therethrough.

In some embodiments, perforation blade 62 (or other type of perforationdevice) may be disposed between transverse sealing elements 46, 46 a asshown. Such positioning conveniently facilitates the placement of lineof weakness 60 between transverse seals 28 a, b of adjacent containers12. Moreover, the creation of a line of weakness 60 in this manneroccurs simultaneously with the creation of seals 28 a, b. However, lineof weakness 60 could also be formed in a separate step, e.g., with aperforation device that is separately positioned and independentlyoperated from first rotary sealing device 20 if desired.

If desired, each container 12 may be separated by a line of weakness 60.Alternatively, fewer numbers of weakness lines 60 may be employed suchthat not every container is separated from an adjacent container by aline of weakness.

For example, a perforation blade could be independently operated and/orseparately positioned to create lines of weakness between any desirednumber of containers, e.g., between every other container, every thirdcontainer, every tenth container, etc. This may be desirable when makingcomplex cushions containing groups of two or more inflated articles.

As a further feature that may be employed with respect to sealing roller48, transverse sealing elements 46, 46 a, and optionally perforationblade 62, may be mounted together as an integral unit on the sealingroller. As shown in FIG. 3, this may be accomplished by mounting thesealing elements 46, 46 a and perforation blade 62 on a support bar 64.Support bar 64, in turn, may be affixed to the surface 56 of sealingroller 48. If desired, the support bar may be removably affixed to thesealing roller, such that the entire assembly may be removed andreplaced as an integral unit. In this manner, when the sealing elementsand/or perforation blade become worn, the whole assembly may be removedand replaced as a unit without the need to replace individualcomponents, thereby facilitating in-field repairs.

The support bar 64 may be attached to sealing roller 48 via any suitablemeans, such as a pair of retaining pins 66, which may be connected toand extend through the support bar and be retained in correspondingsockets (not shown) in sealing roller 48, e.g., via friction fit, toprovide mechanical attachment of the bar to the roller. The portion ofpins 66 extending from support bar 64, as shown in FIG. 3, providegrasping surfaces to facilitate the manual removal and replacement ofthe integral ‘sealing assembly,’ i.e., support bar 64 with transversesealing elements 46, 46 a and perforation blade 62 mounted thereto.Further, when sealing elements 46, 46 a are wires or other devices thatgenerate heat by providing resistance to the flow of electrical currenttherethrough, retaining pins 66 may also be used to provide electricalconnection for the sealing elements 46, 46 a, i.e., by providingelectrical communication between a source of electricity (not shown) andthe sealing elements. A suitable type of pin in this regard is known asa “banana plug.” Thus, for example, a carbon-brush commutator and slipring may be used to transfer electricity from a static source, e.g., awire from a wall socket, to the rotating sealing elements, whereby thecarbon brushes are stationary and transfer electrical current to theslip ring, which is attached to and rotates with sealing roller 48. Theslip ring, in turn, is in electrical communication with the pins 66.

Further details regarding the first sealing device 20 as shown in FIG. 3are disclosed in the above-incorporated U.S. Ser. No. 11/099,289,published under Publication Number US-2006-0218880-A1.

As noted above, second sealing device 24 produces longitudinal seal 34between film plies 16, 18, which intersects pair 28 a, b of transverseseals 26 to enclose gas 32 within pre-inflated containers 30. In thismanner, the containers 30 are converted into inflated containers 12.

As shown in FIGS. 1-2, second sealing device 24 may include a rotarycomponent, such as sealing roller 70, and a backing roller 68. As withthe first sealing device 20, the sealing and backing rollers 70, 68 ofdevice 24 rotate against one another to create a ‘nip,’ or area oftangential contact, therebetween, which exerts a rotational compressiveforce on film web 14. As such, sealing and backing rollers 70, 68 may,in addition or as an alternative to first sealing device 20, facilitatethe conveyance of the film web through apparatus 10 when the rollersrotate in the direction indicated by the rotational arrows. The rotationof one or both of rollers 70, 68 may be powered by a suitable drivemechanism, e.g., motor 72, as shown schematically in FIG. 2.

Longitudinal seal 34 may be any type of seal that bonds two film pliestogether, such as a heat seal, adhesive seal, cohesive seal, etc., withheat seals being preferred as noted above. Longitudinal seal 34 isgenerally oriented in a direction that is substantially parallel to thedirection of movement of film web 14 along its travel path throughapparatus 10. As shown in FIG. 2, seal 34 may be a continuouslongitudinal seal, i.e., a substantially linear, unbroken seal, which isinterrupted only when second sealing device 24 is caused to stop makingthe seal. Thus, sealing roller 70 may be heated in any suitable mannerto produce a continuous longitudinal seal 34 as shown. For example, thesecond sealing device 24 may include a longitudinal sealing element 71,e.g., an electrically-heated resistive sealing element, such as a bandor wire. Further, sealing roller 70 may be adapted to bring suchlongitudinal sealing element 71 into rotational contact with film web 14to form longitudinal seal 34 as the web is conveyed along its path oftravel. As shown, this may be accomplished by mounting the sealingelement 71 on the circumferential surface of sealing roller 70 thatrotates against the film web.

As an alternative to a continuous longitudinal seal 34 as shown in FIG.2, second rotary sealing device 24 may be adapted to produce adiscontinuous series of longitudinal seals 74, as shown in FIG. 4. Whenthis embodiment is employed, the first and second sealing devices 20, 24are synchronized such that each longitudinal seal 74 intersects thetransverse seals 28 a, b that define each pre-inflated container 30,thereby enclosing gas 32 therewithin to complete the formation of theinflated containers 12. Thus, leading end 76 of each discontinuouslongitudinal seal 74 intersects the ‘downstream’ transverse seal 28 b ofeach container while the trailing end 78 intersects the ‘upstream’transverse seal 28 a of each container, as shown in FIG. 4.

A discontinuous series of longitudinal seals 74 will result when sealingroller 80, as depicted in FIG. 5, is used in place of sealing roller 70in apparatus 10, i.e., as an alternative sealing roller in secondsealing device 24. Sealing roller 80 may, as shown in FIG. 5, include arotatable support cylinder 82 having an outer, circumferential surface84, and a longitudinal sealing element 86 disposed about at least aportion of the outer surface 84. Sealing element 86 may be secured tocylinder 82 such that the sealing element rotates with the cylinder.

Longitudinal sealing element 86 is preferably a resistive element, whichproduces heat when electricity is supplied thereto (source not shown),and can have any desired shape or configuration. As shown, element 86 isin the form of a wire. When sealing element 86 is a resistive element,support cylinder 82 may be formed from any material that is capable ofwithstanding the temperatures generated by the sealing element. Suchmaterials include metal, e.g., aluminum (preferablyelectrically-insulated); high-temperature-resistant polymers, e.g.,polyimide; ceramics; etc. A groove 91 may be provided in outer surface84 to accommodate sealing element 86 and keep it in proper position onthe outer surface of cylinder 82.

If desired or necessary, a release layer/heat transfer medium may befastened to outer surface 84 such that it is positioned betweenlongitudinal sealing element 86 and the film web 14, such as a coatingof PTFE, e.g., TEFLON tape, spray-on TEFLON coating, polyester, or othermaterial capable of withstanding the heat from the sealing element andtransferring the same to the film web in an amount sufficient to createthe longitudinal seals 74. Such a heat transfer medium may be desirablein some applications in order to prevent the heating element fromburning through or sticking to the film web. Sealing roller 70 maysimilarly include such a release layer/heat transfer medium if desiredor necessary.

As shown in FIG. 5, longitudinal sealing element 86 may have a first end88 disposed on the outer surface 84 of cylinder 82, and a second end 90disposed on the outer surface 84. As shown, the first and second ends88, 90 may be spaced from one another such that the sealing element 86forms a helical pattern on the surface 84 of cylinder 78. Such helicalpattern results in the angled configuration of the longitudinal seals 74shown in FIG. 4. At the same time, the helical pattern allows forexpansion and contraction of the sealing element 86 without breaking orbecoming loose on surface 84, which is particularly advantageous whensealing element 86 is a resistive/heating element. Expansion andcontraction of the element 86 occurs due to temperature changes in theelement as it is heated up, e.g., during a warming up period after beingidle, or when it is cooled down, e.g., after apparatus 10 has beenturned off after a period of use.

The expansion/contraction of heating element 82 may be furtheraccommodated by including springs 92 a, b at respective ends 88, 90 ofsealing element 86. The springs may be an integral part of sealingelement 86, or simply connected to ends 88, 90 thereof, and may besecured internally within cylinder 82 via fasteners 94 a, b as shown.

Springs 92 a, b may advantageously exert a tensioning force on sealingelement 86, and thereby keep it taught on surface 84 regardless ofwhether the element is in an expanded or contracted state. The springs92 a, b may be contained within grooves (not shown) in the sides ofcylinder 82. Slots 96 a, b may be included to provide a passage forsealing element 86 between the interior of the cylinder and surface 84thereof as shown.

In some embodiments, the cylinder 82 and sealing element 86 of secondrotary sealing device 24 may be removable and replaceable as an integralunit. In this manner, when sealing element 86 becomes worn, the entiresealing roller 80 may be manually removed and replaced with a freshsealing roller without the need to remove a worn sealing element 86 andinstall a new one on cylinder 82. This feature thus facilitates theserviceability of apparatus 10 for the end-user.

Sealing roller 80 may be removably attached to apparatus 10 in anysuitable manner. For example, the sealing roller may be attached to arotatable hub (not shown) via retaining pins 100 on sealing roller 80,which may be retained in the hub via friction fit, to provide mechanicalattachment of the sealing roller to the hub. When sealing element 86 isa wire or other device that generates heat by providing resistance tothe flow of electrical current therethrough, retaining pins 100 may alsobe electrically conductive and connected to the sealing element 86, andthereby provide electrical communication between a source of electricityand the heating element. As noted above, a suitable type of pin in thisregard is known as a “banana plug.” Thus, for example, a carbon-brushcommutator/slip-ring combination (not shown) may be used to transferelectricity from a static source, e.g., wires from a wall socket orother source, to the sealing roller 80.

Further details regarding sealing roller 80, as an alternative componentof second sealing device 24, are disclosed in the above-incorporatedU.S. Ser. No. 11/099,289, published under Publication NumberUS-2006-0218880-A1.

As a further alternative, the longitudinal sealing element may bearranged on the sealing roller as an overlapping helical pattern, e.g.,as a ‘double helix.’ That is, whereas longitudinal sealing element 86 iscoiled once around the circumferential surface 84 of cylinder 82 to forma ‘single helix,’ in this alternative embodiment, the longitudinalsealing element may be coiled more than once, i.e., overlapped, aboutthe support cylinder, e.g., to form a double helical pattern. Such anarrangement is shown in FIG. 18, which depicts alternative sealingroller 180. Sealing roller 180 includes a longitudinal sealing element186, which is double wound, i.e., coiled twice, about the outer,circumferential surface 184 of rotatable support cylinder 182. In otherembodiments, the sealing element may be coiled two or more times aboutthe outer surface of the cylinder to form at least a double helicalpattern.

The longitudinal sealing element 186 may be secured to cylinder 182, andbe supplied with electrical current, in the same manner as describedabove relative to sealing roller 80, i.e., with internal springs (notshown) to secure the end portions 188, 190 of the sealing element, andspaced apart slots 196 a, b to provide passageways for the end portions188, 190 to traverse between the interior of the cylinder 182 and outer,circumferential surface 184 thereof. Moreover, a groove 191 may beprovided in outer surface 184 to accommodate sealing element 186 andmaintain it in a desired position on the outer surface of cylinder 182.

As with sealing roller 80, sealing roller 180 may be synchronized withfirst sealing device 20 so that the resultant discontinuous longitudinalseals intersect the transverse seals 28 a, b to enclose the gas withinthe resultant inflated containers. FIG. 19 is a plan view of twoadjacent inflated containers 12′, which have been sealed closed withdiscontinuous longitudinal seals 174 by sealing roller 180 (intermediateseals 40 have been omitted for clarity). In this embodiment, thelongitudinal sealing element 186 has sufficient length, and sealingroller 180 is appropriately synchronized with first sealing device 20,such that each longitudinal seal 174 produced seals closed two adjacentinflated containers 12′. For each seal 174 produced, the leading end 176intersects the ‘downstream’ transverse seal 28 b of each container whilethe trailing end 178 intersects the ‘upstream’ transverse seal 28 a ofeach container (in FIG. 19, only one complete seal 174 is shown; theremaining seals 174 are partially shown). Because of the double woundconfiguration of longitudinal sealing element 186, each longitudinalseal 174 is partially overlapped by preceding and succeedinglongitudinal seals, such that each container 12′ is sealed closed by apair of substantially parallel longitudinal seals 174 as shown. As maythus be appreciated, the overlapping, e.g., double-wound, helicalpattern of longitudinal sealing element 186 provides redundantlongitudinal seals, which may lead to a higher total percentage ofnon-leaking inflated containers.

FIG. 20 illustrates an alternate longitudinal seal pattern that mayresult from a lack of synchronization between sealing roller 180 andfirst sealing device 20, such that the leading and trailing ends 176,178 of the longitudinal seals 174 are formed between the transverseseals 28 a, b of the resultant inflated containers 12″. While stillproducing an intersection between transverse seals 28 a, b andlongitudinal seals 174 to enclose gas between the film plies, thisalternative seal pattern advantageously does not require synchronizationbetween the first and second sealing devices. Thus, while the sealpattern shown in FIG. 20 does not provide the redundancy of the sealpattern of FIG. 19, the non-synchronization between the first and secondsealing devices may allow for a simplified set-up of apparatus 10.

Yet another alternative sealing roller that may be used in secondsealing device 24 is a type of device known as a “drag sealer,” whichincludes a stationary heating element that is placed between a pair ofrotating nip rollers and in direct contact with a pair of moving filmplies to create a continuous longitudinal seal. Such devices aredisclosed, e.g., in U.S. Pat. Nos. 6,550,229 and 6,472,638, thedisclosures of which are hereby incorporated herein by reference.

A further alternative sealing device which may be used for second rotarysealing device 24 is a type of device known as a “band sealer,” whichincludes a pair of sealing bands that counter-rotate against one anotheraround a plurality of guide rollers, with a heating element in contactwith the inner track of one or both bands. A pair of film plies movebetween, and are sealed together by, the bands. Such devices aredisclosed, e.g., in U.S. Ser. No. 10/979,583, filed Nov. 2, 2004 andpublished under publication number US-2006-0090421-A1, the disclosure ofwhich is hereby incorporated herein by reference.

Backing rollers 38 and 68 may both be formed from a pliant material,such as, e.g., rubber or RTV silicone. Other materials, e.g., metalrollers with a knurled surface, may also be used as desired.

Intermediate sealing elements 26, transverse sealing elements 46, andlongitudinal sealing element 86 may comprise one or more wires made frommetal or other electrically conductive material; one or more metallicribbons; circuit-printed plastic ribbons, e.g., metal printed on aplastic substrate comprising polyethylene terephthalate (PET); and othersuitable electrically conductive devices. Examples of suitable metallicmaterials include, e.g., nichrome, steel, copper, etc. When sealingelements 26, 46, and 86 are in the form of a wire or ribbon, it may haveany desired cross-sectional shape, including round, square, oval,rectangular, etc. Sealing elements 26, 46, and 86 may be made by anyconventional method. One method that has been found suitable is tochemically-etch a metallic sheet or plate, e.g., 316 stainless steel,into a desired pattern. Using this method, the sealing elements may eachbe formed from a single, continuous piece of metal.

Film web 14 may, in general, comprise any flexible material that can bemanipulated by apparatus 10 to produce inflated containers as hereindescribed, including various thermoplastic materials, e.g., polyethylenehomopolymer or copolymer, polypropylene homopolymer or copolymer, etc.Non-limiting examples of suitable thermoplastic polymers includepolyethylene homopolymers, such as low density polyethylene (LDPE) andhigh density polyethylene (HDPE), and polyethylene copolymers such as,e.g., ionomers, EVA, EMA, heterogeneous (Zeigler-Natta catalyzed)ethylene/alpha-olefin copolymers, and homogeneous (metallocene,single-cite catalyzed) ethylene/alpha-olefin copolymers.Ethylene/alpha-olefin copolymers are copolymers of ethylene with one ormore comonomers selected from C3 to C20 alpha-olefins, such as 1-butene,1-pentene, 1-hexene, 1-octene, methyl pentene and the like, in which thepolymer molecules comprise long chains with relatively few side chainbranches, including linear low density polyethylene (LLDPE), linearmedium density polyethylene (LMDPE), very tow density polyethylene(VLDPE), and ultra-low density polyethylene (ULDPE). Various otherpolymeric materials may also be used such as, e.g., polypropylenehomopolymer or polypropylene copolymer (e.g., propylene/ethylenecopolymer), polyesters, polystyrenes, polyamides, polycarbonates, etc.The film may be monolayer or multilayer and can be made by any knownextrusion process by melting the component polymer(s) and extruding,coextruding, or extrusion-coating them through one or more flat orannular dies.

As noted hereinabove, apparatus 10 further includes an inflationassembly 22 for placing gas between the film plies 16, 18. Inflationassembly 22 may be any device that places gas between the film plies. Inthe illustrated embodiment, the inflation assembly 22 inflatescontainers 30 by directing a stream of gas 32 between the film plies 16,18 and into the opening of each container at open longitudinal edge 38.Inflation assembly 22 may include a nozzle 102 from which the stream ofgas 32 exits the inflation assembly, and a source 104 of such gas (seeFIG. 2). Gas 32 may be, e.g., air, nitrogen, carbon dioxide, etc. Gassource 104, which is shown schematically and labeled “S” in FIG. 2, maybe, e.g., compressed gas, such as from one or more tanks, from a centralcompressor that supplies compressed gas to an entire facility, or from asmaller compressor dedicated only to apparatus 10. Gas source 104 mayalso be a blower, fan, or any conventional device for supplying and/ormoving gas.

As shown in FIG. 2, nozzle 102 may protrude into the open longitudinaledge 38 to effect the inflation of containers 30. This may befacilitated by adapting first sealing device 20 to make transverse seals28 such that they extend from the closed longitudinal edge 36 andterminate a predetermined distance from the open longitudinal edge 38.In this manner, each of the juxtaposed film plies 16, 18 have flanges106 at the open longitudinal edge that are not bonded together. As shownperhaps most clearly in FIG. 4, such flanges 106 extend along the openlongitudinal edge 38. Thus, flanges 106 are longitudinally extendingedge sections of film plies 16, 18 that extend beyond the ends of thetransverse seals 28 and, therefore, are not bonded together, i.e., byseals 28 or any other means. Accordingly, at least a portion of thenozzle 102 may be positioned between the flanges 106 so that, as filmweb 14 is conveyed along its travel path through apparatus 10, thenozzle moves longitudinally between the flanges. Alternatively, if edge38 is a closed edge, a slitter may be positioned upstream of nozzle 102to slit such edge and thereby allow the nozzle to remain positionedbetween the film plies 16, 18 as shown. In both cases, nozzle 102 mayremain in a fixed position while film web 14 moves continuously past thenozzle.

In other embodiments, inflation assembly 22 may direct gas between thefilm plies by pulling gas between the film plies, e.g., by manipulatingthe film plies in such a way that a slight negative pressure is createdin a void space between the film plies to draw gas, e.g., air, into thevoid space. Further details concerning this manner of inflation are setforth in U.S. Ser. No. 11/372,684, published under Publication No.US-2006-0201960-A1, the disclosure of which is hereby incorporatedherein by reference thereto. In still other embodiments, inflationassembly 22 may direct gas between the film plies by manipulating thefilm plies in such a way that gas at ambient pressure is simply trappedbetween the film plies.

Referring now to FIG. 6, one embodiment of the intermediate sealingelements 26 will be described, In such embodiment, intermediate sealingelements 26 may be secured to the surface 108 of individual insulatedsupport members 110. Insulated support members 110 may be containedwithin recesses 111 a in sealing roller 48 as shown, e.g., such that thesurfaces 108 of the support members 110 are substantially flush withsurface 56 of the sealing roller 48. Support members 110 may be securedvia internal connectors 112 (only one shown), which may be positionedinside of sealing roller 48 as shown. Internal connectors 112 are inelectrical communication with a source of electricity (not shown), e.g.,via wire leads 114 a, b, which may be connected to a pair of wires (notshown) contained within the interior of sealing roller 48. Each lead 114a, b may, in turn, be connected to a separate end of each sealingelement 26. In this manner, electricity can be made to flow through eachof the intermediate sealing elements 26, 26 a, and 26 b to form therespective intermediate seals 40, 40 a, and 40 b.

If desired, intermediate sealing elements 26, 26 a, and 26 b may beelectrically connected in series in the foregoing manner such thatrespective intermediate seals 40, 40 a, and 40 b may be formed as a‘set’. An opposing ‘set’ of intermediate sealing elements 26 c-26 e maybe identically contained and electrically connected in correspondingrecesses 111 b on the opposing side of sealing roller 48 as indicated inFIG. 6. In this manner, the set of sealing elements 26-26 b may beoperated independently from the set of sealing elements 26 c-26 e. Thismay be desired, e.g., to produce alternating compartmented andnon-compartmented containers 12.

If further desired, transverse sealing element pair 46/46 a may beoperated as a ‘set’ while opposing transverse sealing element pair 46b/46 c may be operated independently as another ‘set.’ Both pairs mayalso be operated independently from the intermediate sealing elementsets. This may be accomplished by equipping sealing roller 48 with four(4) separate pairs of commutator rings (not shown), which may be spacedfrom and co-axial with the sealing roller, i.e., such that thecommutator rings rotate about axis 58 along with the sealing roller,Each commutator ring pair may be supplied with a separate source ofelectricity and be in electrical communication with a separate one ofthe four sets of sealing elements, i.e., (1) intermediate sealing set26-26 b, (2) transverse sealing set 46/46 a, (3) intermediate sealingset 26 c-26 e, and (4) transverse sealing set 46 b/46 c. Thisconfiguration allows independent control of each set of sealingelements, thereby allowing container-length to be varied as desired on areal time basis, i.e., without having to change sealing rollers, byvarying the web-length between actuation of the transverse sealingelements and varying the actuation of the intermediate sealing elementsaccordingly.

If desired, each internal connector 112 may be used to secure andelectrically connect a pair of intermediate sealing elements. Thus,opposing sealing elements 26 and 26 c may be secured to the sameconnector 112; opposing sealing elements 26 a and 26 d may be secured tothe same connector 112; and opposing sealing elements 26 b and 26 e maybe secured to the same connector 112 as shown. If groups of intermediatesealing elements on the same side of sealing roller 48 are to beoperated as ‘sets’ as described above, each sealing element in theopposing pair thereof will have a separate pair of wire leads 114, willbe insulated from one another, and will be supplied with electricity bya separate set of wires inside of the sealing roller. Alternatively, thesame set of wires and wire leads may be used to supply both elements ina pair if the pair is not operated independently. Thus, for example,wire leads 114 a, b may be used to supply electrical current to bothintermediate sealing element 26 a and opposing intermediate sealingelement 26 d.

Referring now to FIGS. 7-8, another embodiment of an apparatus formaking inflated containers in accordance with the present invention willbe described. Such apparatus, designated by the reference numeral 200,is similar to apparatus 10, except that the intermediate sealing elementis a component of a third sealing device 202, rather being a componentof the first sealing device as in apparatus 10. That is, in thisembodiment, the intermediate sealing element is a component of adedicated sealing device, which produces intermediate sealsindependently of the first sealing device, which produces transverseseals. In the following description, where components employed inapparatus 10 may also be employed in apparatus 200 or other embodimentsin accordance with the present invention, they will be indicated by thesame reference number. However, this convention should not be construedas limiting in any way, as other variations are possible and entirelywithin the scope of the present invention.

Apparatus 200 makes inflated containers 204 from film web 14 having twojuxtaposed film plies 16 and 18. As with apparatus 10, apparatus 200includes a first sealing device 206, which produces a series oftransverse seals 28 that bond the juxtaposed film plies 16, 18 together;an inflation assembly 22, which directs gas 32 between film plies 16, 18and into pre-inflated containers 208; a second sealing device 24, whichproduces one or more longitudinal seals 34 that bond the film plies 16,18 together; and at least one intermediate sealing element 210 forproducing one or more intermediate seals 212 within each inflatedcontainer 204. As shown, transverse seals 28 and longitudinal seal 34are formed in such a manner that the seals 28, 34 intersect, therebyenclosing gas 32 between film plies 16, 18.

First sealing device 206 may be substantially as shown and describedwith respect to FIG. 3, and may optionally include a second pair oftransverse sealing members 46 b and 46 c as shown in FIG. 7. Thus, thefirst sealing device 206 may include a rotary component or sealingroller 214 which, like sealing roller 48, is adapted to bring transversesealing elements 46-46 c into rotational contact with film web 14 toform transverse seals 28 therein as the film web is conveyed along itspath of travel through apparatus 200. Backing roller 50 as describedabove may also be employed as shown. As also described above, thesealing and backing rollers 214, 50 may thus be used to convey film web14 through apparatus 200 when the rollers rotate in the directionindicated by the rotational arrows in FIG. 7, which thereby drives thefilm web in a forward direction as indicated by the linear arrow in FIG.8.

Second sealing device 24 may produce a continuous longitudinal seal 34as shown in FIG. 8 or, as described above, be adapted to produce adiscontinuous series of longitudinal seals 74 or 174, as shown in FIGS.4, 19 and 20, wherein each such longitudinal seal 74, 174 intersects thetransverse seals 28 a, b that define each pre-inflated container 208.

In the presently-illustrated embodiment, third sealing device 202includes three intermediate sealing elements 210, 210 a, and 210 b,which form three columns of intermittent or discontinuous intermediateseals 212, 212 a, and 212 b in film web 14. As shown, the intermediateseals 212-212 b partition the inflated containers 204 into two or morecompartments 216 a-216 d, and provide at least one flow passageway 218between compartments 216 a-216 d to allow such compartments to fluidlycommunicate with one another.

Third sealing device 202 may further include at least one rotarycomponent, which is adapted to bring the intermediate sealing element(s)into rotational contact with film web 14 as the web is conveyed alongits path of travel. In the presently-illustrated embodiment, this isaccomplished by mounting the intermediate sealing elements 210-210 b onindividual rotatable cylinders 224-224 b, respectively. Cylinders224-224 b may be independently operated or, as shown, mechanicallycoupled via axle 226. Alternatively, the sealing elements 210-210 b maybe mounted on a single roller. As shown, cylinders 224-224 b withsealing elements 210-210 b thereon rotate against backing roller 50 in ashared relationship with first sealing device 206. In this manner, thirdsealing device 202 forms the intermediate seals 212-212 b as the filmweb is conveyed along its path of travel.

FIG. 9 illustrates one form of sealing element 210, which may be used inthird sealing device 202 to make the intermediate seals 212-212 b asshown in FIG. 8. Sealing element 210, and also sealing elements 210 a,b, may include seal segments 220 and non-seal segments 222. Whenelectrical current is made to flow through the sealing element, sealsegments 220 heat to a temperature sufficient to form a heat sealbetween film plies 16, 18. In contrast, when current flows through thesealing element 210, non-seal segments 222 preferably do not heatsufficiently to form a heat seal. Thus, as the cylinders 224-224 brotate against film web 14, the film web is alternatingly contacted by aseal segment 220 and a non-seal segment 222, thereby periodically‘skipping’ the formation of the intermediate seals within each column.In this manner, individual, longitudinally-spaced columns ofintermediate ‘skip seals’ 212-212 b are formed in film web 14 as shownto segment each inflated container 204 into two or more compartments 216a-216 d.

Sealing elements 210-210 b may be formed by chemically etching asuitable material, e.g., a piece of metal such as 316 stainless steel,in which seal segments 220 are chemically etched to be of lessercross-sectional area, i.e., thickness, than the non-seal segments 222.The thinner seal segments 220 will thus offer greater resistance to theflow of electrical current than the thicker non-seal segments 222, andthereby heat up to a greater extent than the non-seal segments. Usingthis method, the sealing elements 210-210 b may each be formed from asingle, continuous piece of metal. Alternatively, separate pieces ofmaterial having different thicknesses and/or different electricalresistivities may be joined together to form the sealing elements withdiscrete seal and non-seal segments.

The sealing elements 210-210 b may be joined to the outer,circumferential surface of cylinders 224-224 b in the same manner asdescribed above with respect to FIG. 5, i.e., the same way thatlongitudinal sealing element 86 is mounted to cylinder 82. Thus, eachsealing element 210-210 b may include a pair of springs 228, one at eachend of the sealing element, with each spring terminating in a mountingeyelet 230 to allow the sealing element to be secured, e.g., internallysecured, to the cylinders 224.

Referring now to FIGS. 10-11, another embodiment of an apparatus formaking inflated containers in accordance with the present invention willbe described. Such apparatus, designated by the reference numeral 300,makes inflated containers 304 from film web 14 or any other film havingtwo juxtaposed film plies, e.g., plies 16 and 18. Apparatus 300 includesa first sealing device 306, which produces a series of transverse seals28 that bond the juxtaposed film plies 16, 18 together; an inflationassembly 302, which directs gas 308 between film plies 16, 18; a secondsealing device 24, which produces one or more longitudinal seals 34 thatbond the film plies 16, 18 together; and at least one intermediatesealing element 310 for producing one or more intermediate seals 312within each inflated container 304. As shown, transverse seals 28 andlongitudinal seal 34 are formed in such a manner that the seals 28, 34intersect, thereby enclosing gas 308 between film plies 16, 18.

In this embodiment, first sealing device 306 comprises at least onetransverse sealing element 314, e.g., a pair of transverse sealingelements 314 a, b, and a movable component 316, e.g., a pair of movablecomponents 316 a, b. Movable components 316 a, b are adapted to bringthe transverse sealing elements 314 a, b into contact with film web 14,and move with the film web along at least part of its path of travelthrough apparatus 300. In this manner, the first sealing device 306forms transverse seals 28, e.g., as a pair of transverse seals 28 a, b,as the film web 14 is conveyed along its path of travel, thereby formingthe transversely-oriented boundaries of each inflated container 304.

As illustrated, movable components 316 a, b may be positioned adjacentopposing surfaces of film web 14, and be movable towards one another asindicated by the horizontal arrows such that they engage the film web onopposing surfaces thereof. This causes movable component 316 a to bringtransverse sealing elements 314 a, b into contact with film web 14 toform respective transverse seals 28 a, b. Movable component 316 b servesas a backing or support surface, against which film web 14 is pressed bycomponent 316 a and sealing elements 314 a, b, to facilitate theformation of the transverse seals 28 a, b. As the transverse seals 28are being formed in this manner, the movable components 316 a, b movewith film web 14 along its path of travel, e.g., in a downward directionas indicated. Such movement can occur by the mere fact that the firstsealing device 306 is engaged with, i.e., temporarily attached to, thefilm web. Alternatively or in addition, a separate conveyance mechanismfor the first sealing device 306 may be employed to effect suchmovement.

When a sufficient amount of contact time has elapsed for the transverseseals 28 to form, the movable components 316 a, b may be made to moveapart to disengage from the film web, as indicated by the phantom,divergent arrows in FIGS. 10-11. At this point, the movable components316 a, b will be downstream of their starting position, at an endingposition which is also shown in phantom. A suitable means of conveyance(not shown), e.g., a chain-drive, pneumatic-drive, hydraulic-drive, orscrew-drive mechanism, may be used to move the movable components 316 a,b back upstream to their starting position. The movable components 316a, b may then be made to re-engage film web 14 at any desired time toproduce the next set 28 a, b of transverse seals, thereby producinginflated containers of any desired length.

Accordingly, container-size can thus be varied as desired without havingto change film rolls, and with no sacrifice in production speed sincethe first sealing device 306 moves with the film web. Moreover,apparatus 300 can produce inflated containers of varying length, suchthat two or more adjacent containers in the film web have differentlengths. In this manner, relatively complex cushions comprising two ormore inflated containers of two or more different sizes can be produced.

Any suitable mechanism may be employed to cause movable components 316a, b to converge toward and diverge away from one another, e.g., a pairof actuators (not shown) that may be powered pneumatically,hydraulically, electrically, mechanically, magnetically,electro-magnetically, etc. Transverse sealing elements 314 a, b may beheat seal elements as described above. Further details regarding thefirst sealing device 306 are disclosed in the above-incorporated U.S.Ser. No. 10/979,583, filed Nov. 2, 2004 and published under publicationnumber US-2006-0090421-A1.

Second sealing device 24 may produce a continuous longitudinal seal 34as shown, e.g., in FIG. 2 or, if desired, produce a discontinuous seriesof longitudinal seals 74 or 174 which, as shown in FIGS. 4, 19, and 20,intersect the transverse seals 28 a, b of each inflated container. Forsimplicity, a continuous longitudinal seal 34 is shown in FIG. 11.

In this embodiment, three intermediate sealing elements 310, 310 a, and310 b are illustrated, which produce three corresponding columns ofintermediate seals 312, 312 a, and 312 b. As shown, each column ofintermediate seals 312-312 b are in the form of discontinuous ‘skip’seals, which partition the inflated containers 304 into two or morecompartments 318 a-318 d, and provide at least one flow passageway 320between compartments 318 a-318 d to allow such compartments to fluidlycommunicate with one another. It may be readily appreciated that agreater or lesser number of intermediate sealing elements may beemployed in this and in other embodiments described herein, to produce agreater or lesser number of compartments within the inflated containers.

Intermediate sealing elements 310-310 b may be identical to intermediatesealing elements 210-210 b as described above. Similarly, each sealingelement 310-310 b may be mounted on a rotary component, e.g., individualrotatable cylinders 322-322 b, which are adapted to bring theintermediate sealing elements into rotational contact with film web 14as the web is conveyed along its path of travel. Each cylinder 322-322 bmay rotate against an associated backing roller 323-323 b as shown.

In this embodiment, second sealing device 24 may be operated in parallelwith the intermediate sealing elements 310-310 b. As shown, the secondsealing device 24 and intermediate sealing elements 310-310 b may bepositioned upstream of first sealing device 306, such that intermediateseals 312-312 b and longitudinal seal 34 are formed prior to theformation of transverse seals 28. In some versions, intermediate sealingelements 310-310 b may be operated independently of second sealingdevice 24, i.e., as a “third sealing device” as shown in FIGS. 7-8 anddescribed above with respect to third sealing device 202. In otherversions, intermediate sealing elements 310-310 b may be integrated intosecond sealing device 24, e.g., by connecting cylinders 310-310 b withcylinder 70 via a single axle such as axle 226 as shown in FIG. 8.Alternatively, intermediate sealing elements 310-310 b and longitudinalsealing element 71 may all be mounted on the surface of a singleelongated cylinder such as sealing roller 48 as shown in FIG. 2.

As an alternative to inflation assembly 22 as described above, whichincludes a relatively simple nozzle 102, inflation assembly 302 inapparatus 300 may include manifold 324 with multiple nozzles 326 a-d todirect gas 308 between film plies 16, 18 in a distributed manner asshown in FIG. 11. Each nozzle 326 a-d may be aligned with one of thecompartments 318 a-d as shown to ensure adequate gas flow to eachcompartment. An opposing pair of grooved nip rollers 328 a, b may beincluded to facilitate this process by directing gas flow 308 betweengrooves 329 and into each compartment 318 a-d. Nip rollers 328 a, b mayalso be powered to provide a mechanism for conveying film web 14 alongthe indicated path of travel through apparatus 300.

Referring now to FIGS. 12-15, another embodiment of the invention willbe described. In this embodiment, apparatus 400 makes inflatedcontainers 404 from film web 14 or from any other web having twojuxtaposed film plies, e.g., plies 16 and 18. Apparatus 400 includes afirst sealing device 406, which produces a series of transverse seals 28that bond the juxtaposed film plies 16, 18 together; an inflationassembly 22, which directs gas 32 between film plies 16, 18; a secondsealing device 24, which produces one or more longitudinal seals 34 thatbond the film plies 16, 18 together; and at least one intermediatesealing element 410 for producing one or more intermediate seals 412within each inflated container 404. As shown, transverse seals 28 andlongitudinal seal 34 are formed in such a manner that the seals 28, 34intersect, thereby enclosing gas 32 between film plies 16, 18.

First sealing device 406 may be substantially similar to first sealingdevice 306 as described above and illustrated in FIGS. 10-11. Thus,first sealing device 406 may comprise at least one transverse sealingelement 414, e.g., a pair of transverse sealing elements 414 a, b, and amovable component 416, e.g., a pair of movable components 416 a, b, withboth of transverse sealing elements 414 a, b mounted, e.g., on movablecomponent 416 a. Movable components 416 a, b are adapted to bring thetransverse sealing elements 414 a, b into contact with film web 14, andmove with the film web along at least part of its path of travel throughapparatus 400 as shown, e.g., by moving in a reciprocating path betweenguide rollers 418 and 420 as shown. In this manner, the first sealingdevice 406 forms transverse seals 28, e.g., as a pair of transverseseals 28 a, b, as the film web 14 is conveyed along its path of travel,thereby forming pre-inflated containers 408.

Unlike first sealing device 306, first sealing device 406 is positionedupstream of the inflation assembly and second sealing device. Inaddition, first sealing device 406 may further comprise one or moreintermediate sealing elements 410. Thus, as shown in FIG. 14A forexample, movable component 416 a may include transverse sealing elements414 a, b, and also intermediate sealing elements 410, 410 a, and 410 b.A perforation blade 422 may also be included, e.g., between transversesealing elements 414 a, b, to form lines of weakness between eachcontainer 404 (not shown). An alternative configuration of thetransverse sealing elements 414 a, b, intermediate sealing elements410-410 b, and perforation blade 422 is shown in FIG. 14B. Bothconfigurations will result in the seal pattern shown in FIG. 13.

Accordingly, when first sealing device 406 makes contact with film web14, movable component 416 a thereof brings both the transverse sealingelements 414 a, b and the intermediate sealing elements 410-410 b intocontact with the film web, and thereby forms both the transverse seals28 a, b and corresponding intermediate seals 412, 412 a, and 412 b asthe film web is conveyed along its path of travel. As shown in FIG. 13,the three intermediate sealing elements 410, 410 a, and 410 b producethree corresponding columns of intermediate seals 412, 412 a, and 412 b.As shown, each column of intermediate seals 412-412 b are in the form ofdiscontinuous ‘skip’ seals, which partition the inflated containers 404into two or more compartments 424 a-424 d, and provide at least one flowpassageway 426 between compartments 424 a-424 d to allow suchcompartments to fluidly communicate with one another.

Inflation assembly 22 and second sealing device 24 may be substantiallyas described above. In this embodiment, second sealing device 24provides the mechanism to convey film web 14 along the indicated path oftravel through apparatus 400. Alternatively, a separate mechanism, e.g.,a pair of drive rollers (not shown), may be employed for this purpose.

Referring now to FIGS. 16-17, yet another embodiment of the presentinvention will be described. In this embodiment, apparatus 500 makesinflated containers 504 from film web 14 or any other film having twojuxtaposed film plies, e.g., plies 16 and 18. Apparatus 500 includes afirst sealing device 506, which produces a series of transverse seals 28that bond the juxtaposed film plies 16, 18 together; an inflationassembly, such as inflation assembly 22 as described above, whichdirects gas 32 between film plies 16, 18; a second sealing device, suchas second sealing device 24 as described above, which produces one ormore longitudinal seals 34 that bond the film plies 16, 18 together; andat least one intermediate sealing element 510 for producing one or moreintermediate seals 512 within each inflated container 504. Transverseseals 28 and longitudinal seal 34 are formed in such a manner that theseals 28, 34 intersect, thereby enclosing gas 32 between film plies 16,18.

First sealing device 506 may be substantially similar to first sealingdevice 306 as described above and illustrated in FIGS. 10-11. Inapparatus 500, however, first sealing device 506 is positioned upstreamof the inflation assembly and second sealing device. First sealingdevice 506 may include at least one transverse sealing element 514,e.g., a pair of transverse sealing elements 514 a, b, and a movablecomponent 516, e.g., a pair of movable components 516 a, b, with both oftransverse sealing elements 514 a, b mounted, e.g., on movable component516 b. Movable components 516 a, b are adapted to bring the transversesealing elements 514 a, b into contact with film web 14, and move withthe film web along at least part of its path of travel through apparatus500, e.g., by moving in a reciprocating path upstream of guide roller518 as shown. In this manner, the first sealing device 506 formstransverse seals 28, e.g., as a pair of transverse seals 28 a, b, as thefilm web 14 is conveyed along its path of travel, thereby formingpre-inflated containers 508.

Second sealing device 24 may produce a continuous longitudinal seal 34as shown in FIG. 17 or, as described above, be adapted to produce adiscontinuous series of longitudinal seals 74 or 174, as shown in FIGS.4, 19, and 20, wherein each such longitudinal seal 74, 174 intersectsthe transverse seals 28 a, b that define each pre-inflated container508.

As with apparatus 200 described above in connection with FIGS. 7-9, theintermediate sealing element 510 employed in apparatus 500 is acomponent of a third sealing device 520. As shown, third sealing device520 includes, in addition to sealing element 510, intermediate sealingelements 510 a and 510 b, which form three columns of intermittent ordiscontinuous intermediate seals 512, 512 a, and 512 b in film web 14.Such intermediate seals 512-512 b partition the inflated containers 504into two or more compartments 522 a-522 d, and provide at least one flowpassageway 524 between compartments 522 a-522 d to allow suchcompartments to fluidly communicate with one another.

Third sealing device 520 may further include at least one rotarycomponent, which is adapted to bring the intermediate sealing element(s)into rotational contact with film web 14 as the web is conveyed alongits path of travel. In the presently-illustrated embodiment, this isaccomplished by mounting the intermediate sealing elements 510-510 b onindividual rotatable cylinders 526-526 b, respectively. Cylinders526-526 b may be independently operated or, as shown, mechanicallycoupled with a common axle 530. Alternatively, the sealing elements510-510 b may be mounted on a single roller. As shown, cylinders 526-526b with sealing elements 510-510 b thereon rotate against individualbacking rollers 528-528 b. In this manner, third sealing device 520forms the intermediate seals 512-512 b as the film web is conveyed alongits path of travel.

As shown, second sealing device 24 and/or third sealing device 520 mayconstitute a mechanism to convey film web 14 along the indicated path oftravel through apparatus 500.

The foregoing description of preferred embodiments of the invention hasbeen presented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formdisclosed, and modifications and variations are possible in light of theabove teachings or may be acquired from practice of the invention.

What is claimed is:
 1. An apparatus for forming inflatable containers ina film web having two juxtaposed film plies, the apparatus comprising: atransverse sealing device configured to produce a series of transverseseals in the film web to bond the juxtaposed film plies together; and anintermediate sealing device configured to produce a plurality of columnsof discontinuous intermediate seals in the film web; wherein thetransverse seals form sides of inflatable containers in the film web andthe film web has a closed longitudinal edge that forms a closed end ofthe inflatable containers; wherein the intermediate seals are arrangedto partition each inflatable container into a plurality of compartments;wherein, in each of the inflatable containers, the intermediate sealsprovide at least one flow passageway between compartments to allow thecompartments to fluidly communicate with one another.
 2. The apparatusof claim 1, wherein the transverse sealing device is further configuredto produce a series of pairs of transverse seals in the film web.
 3. Theapparatus of claim 2, wherein the transverse sealing device is furtherconfigured to form a line of weakness between each of the pairs oftransverse seals in the film web.
 4. The apparatus of claim 1, whereinthe intermediate sealing device is configured to produce the pluralityof columns of discontinuous intermediate seals in the film web such thatthe intermediate seals do not intersect the transverse seals.
 5. Theapparatus of claim 1, wherein the intermediate sealing device isconfigured to produce the plurality of columns of discontinuousintermediate seals in the film web such that a first set of theintermediate seals intersect the transverse seals.
 6. The apparatus ofclaim 5, wherein the intermediate sealing device is configured toproduce the plurality of columns of discontinuous intermediate seals inthe film web such that a second set of the intermediate seals do notintersect the transverse seals.
 7. The apparatus of claim 1, wherein thefilm web is configured to move along a path of travel through theapparatus, and wherein the intermediate sealing device is upstream ofthe transverse sealing device along the path of travel.
 8. A method offorming inflatable containers in a film web having two juxtaposed filmplies, the method comprising: producing, by a transverse sealing device,a series of transverse seals in the film web to bond the juxtaposed filmplies together; and producing, by an intermediate sealing device, aplurality of columns of discontinuous intermediate seals in the filmweb; wherein the transverse seals form sides of inflatable containers inthe film web and the film web has a closed longitudinal edge that formsa closed end of the inflatable containers; wherein the intermediateseals are arranged to partition each inflatable container into aplurality of compartments; wherein, in each of the inflatablecontainers, the intermediate seals provide at least one flow passagewaybetween compartments to allow the compartments to fluidly communicatewith one another.
 9. The method of claim 8, wherein producing thetransverse seals comprises producing a series of pairs of transverseseals in the film web.
 10. The method of claim 9, wherein producing thetransverse seals further comprises forming a line of weakness betweeneach of the pairs of transverse seals in the film web.
 11. The method ofclaim 8, wherein producing the plurality of columns of discontinuousintermediate seals in the film web comprises producing the intermediateseals such that the intermediate seals do not intersect the transverseseals.
 12. The method of claim 8, wherein producing the plurality ofcolumns of discontinuous intermediate seals in the film web comprisesproducing the intermediate seals such that a first set of theintermediate seals intersect the transverse seals.
 13. The method ofclaim 12, wherein the intermediate sealing device is configured toproduce the plurality of columns of discontinuous intermediate seals inthe film web such that a second set of the intermediate seals do notintersect the transverse seals.
 14. The method of claim 8, whereinproducing the plurality of columns of discontinuous intermediate sealsin the film web is performed in before producing the series oftransverse seals in the film web.